US7294844B2 - Lithographic apparatus, device manufacturing method, and device manufactured thereby - Google Patents
Lithographic apparatus, device manufacturing method, and device manufactured thereby Download PDFInfo
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- US7294844B2 US7294844B2 US10/894,368 US89436804A US7294844B2 US 7294844 B2 US7294844 B2 US 7294844B2 US 89436804 A US89436804 A US 89436804A US 7294844 B2 US7294844 B2 US 7294844B2
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- G03F—PHOTOMECHANICAL PRODUCTION OF TEXTURED OR PATTERNED SURFACES, e.g. FOR PRINTING, FOR PROCESSING OF SEMICONDUCTOR DEVICES; MATERIALS THEREFOR; ORIGINALS THEREFOR; APPARATUS SPECIALLY ADAPTED THEREFOR
- G03F7/00—Photomechanical, e.g. photolithographic, production of textured or patterned surfaces, e.g. printing surfaces; Materials therefor, e.g. comprising photoresists; Apparatus specially adapted therefor
- G03F7/70—Microphotolithographic exposure; Apparatus therefor
- G03F7/70483—Information management; Active and passive control; Testing; Wafer monitoring, e.g. pattern monitoring
- G03F7/70491—Information management, e.g. software; Active and passive control, e.g. details of controlling exposure processes or exposure tool monitoring processes
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- G03F7/70—Microphotolithographic exposure; Apparatus therefor
- G03F7/70425—Imaging strategies, e.g. for increasing throughput or resolution, printing product fields larger than the image field or compensating lithography- or non-lithography errors, e.g. proximity correction, mix-and-match, stitching or double patterning
- G03F7/70466—Multiple exposures, e.g. combination of fine and coarse exposures, double patterning or multiple exposures for printing a single feature
Definitions
- the present invention relates to a lithographic apparatus, a device manufacturing method, and a device manufactured thereby.
- Lithographic apparatus can be used, for example, in the manufacture of integrated circuits (ICs).
- a patterning device may be used to generate a desired circuit pattern corresponding to an individual layer of the IC, and this pattern can be imaged onto a target portion (e.g. comprising one or more dies) on a substrate (silicon wafer) that has been coated with a layer of radiation-sensitive material (resist).
- a target portion e.g. comprising one or more dies
- substrate silicon wafer
- resist radiation-sensitive material
- patterning device as here employed should be broadly interpreted as referring to a device that can be used to impart an incoming radiation beam with a patterned cross-section, corresponding to a pattern that is to be created in a target portion of the substrate; the term “light valve” can also be used in this context.
- the pattern will correspond to a particular functional layer in a device being created in the target portion, such as an integrated circuit or other device (see below). Examples of such patterning devices include:
- a single wafer will contain a whole network of adjacent target portions that are successively irradiated via the projection system, one at a time.
- current apparatus employing patterning by a mask on a mask table/holder/holder, a distinction can be made between two different types of machine.
- each target portion is irradiated by exposing the entire mask pattern onto the target portion in one go; such an apparatus is commonly referred to as a wafer stepper.
- each target portion is irradiated by progressively scanning the mask pattern under the projection beam in a given reference direction (the “scanning” direction) while synchronously scanning the substrate table/holder/holder parallel or anti-parallel to this direction.
- the projection system will have a magnification factor M (generally ⁇ 1)
- M magnification factor
- the speed V at which the substrate table/holder/holder is scanned will be a factor M times that at which the mask table/holder/holder is scanned.
- a pattern (e.g. in a mask) is imaged onto a substrate that is at least partially covered by a layer of radiation-sensitive material (resist).
- the substrate Prior to this imaging step, the substrate may undergo various procedures, such as priming, resist coating and a soft bake. After exposure, the substrate may be subjected to other procedures, such as a post-exposure bake (PEB), development, a hard bake and measurement/inspection of the imaged features.
- PEB post-exposure bake
- This array of procedures is used as a basis to pattern an individual layer of a device, e.g. an IC.
- Such a patterned layer may then undergo various processes such as etching, ion-implantation (doping), metallization, oxidation, chemo-mechanical polishing, etc., all intended to finish off an individual layer. If several layers are required, then the whole procedure, or a variant thereof, will have to be repeated for each new layer. Eventually, an array of devices will be present on the substrate (wafer). These devices are then separated from one another by a technique such as dicing or sawing, whence the individual devices can be mounted on a carrier, connected to pins, etc.
- the projection system may hereinafter be referred to as the “lens”; however, this term should be broadly interpreted as encompassing various types of projection system, including refractive optics, reflective optics, and catadioptric systems, for example, whereby any of these types of projection system may either be suitable for conventional imaging or be suitable for imaging in the presence of an immersion fluid.
- the radiation system may also include components operating according to any of these design types for directing, shaping, or controlling the projection beam of radiation, and such components may also be referred to below, collectively or singularly, as a “lens”.
- the lithographic apparatus may be of a type having two or more substrate tables/holders (and/or two or more mask tables/holders).
- a lithographic apparatuses are designed and manufactured to meet certain specifications of device manufacturers.
- the specifications usually comprise details with regard to the accuracy of the processes to be carried out with the lithographic apparatus as well as the number of devices which can be made per unit of time with one lithographic apparatus, i.e. the throughput of one apparatus.
- the accuracy with which processes are carried out may affect the smallest size of functional features which can be produced on a substrate, using the lithographic apparatus.
- the apparatus is usually designed such that processes are carried out with a particular accuracy whilst achieving a particular throughput.
- the lithographic apparatus comprises a substrate holder configured to hold a substrate; a radiation system configured to condition a beam of radiation; a support structure configured to support a patterning device that imparts a desired pattern onto the beam of radiation; a projection system that projects the patterned beam onto a target portion of the substrate; and a selection system that selects one out of at least two different operational modes of the lithographic apparatus.
- the first operational mode is associated with performing a process within a first time period at a first level of accuracy and a second operational mode is associated with performing the process within a second time period at a second level of accuracy.
- the first time period is shorter than the second time period and the first level of accuracy is lower than the second level of accuracy.
- a manufacturer of devices is able to manufacture in for instance a first period of time, a number of devices which only need to meet relatively low accuracy specifications, and, after using the selection system, to manufacture, in a second period of time, a number of devices which need to meet relatively high accuracy requirements. If the first period of time and the second period of time are of equal length, the number of devices produced in the first period will be higher than the number of devices produced in the second period. However, although the throughput is less in the second period; the manufacturer saves money due to the fact that only one lithographic apparatus needs to be purchased, if the apparatus concerns an apparatus according to the invention. As a result, the devices can be produced with relatively low costs.
- the different operational modes only differ in the period of time in which a process is performed and in the level of accuracy involved. In other words, throughput and accuracy of the features on a device are coupled. Selecting an operational mode allows thus for selecting a particular throughput and accuracy of the devices to be produced.
- the selection system is arranged to be controlled by a user. This ensures that no technician of the manufacturer of the lithographic apparatus needs to be called out to adapt the apparatus such that one out of the at least two different operational modes is selected.
- the apparatus does also not need to be transported back to the manufacturer of the apparatus or a service center.
- the user-controllability of the selection system allows for flexibility in the use of the apparatus, ultimately leading to lower costs of the devices produced with the apparatus.
- the selection system is controllable via a user-interface.
- the apparatus and the selection system are user-friendly.
- the user-interface may comprise a display with a touch screen or a keyboard to conveniently control the selection system. No particular skills will be required from the user.
- the selection system is arranged to allow for selection of one out of a number of operational modes, the number being larger than two.
- a large number of combinations of time for a particular process which is to be carried out by the lithographic apparatus and accuracy with which that process is to be carried out is selectable, allowing for even more versatile use of the apparatus, for instance depending on the needs.
- the number of operational modes are related to each other according to a predetermined relationship which can be visualized in a graph as a line.
- the line is continuous and/or free from steps, allowing for pricing of the devices produced more or less in relation to the time used by the apparatus for the production of a certain number of devices. Hiring out the apparatus for a period of time is for instance possible, also when potential clients have mutually different needs.
- the process comprises at least one selected from the group consisting of: transporting the substrate and/or substrate table, settling of the substrate after transport, aligning the radiation system, settling of the radiation system after aligning, aligning of the support structure, settling of the support structure after aligning, aligning of the patterning device, settling of the patterning device after aligning, aligning of the projection system, settling of the patterning device after aligning, tilting of the substrate, settling after tilting, focusing of the projection system, exposing of the substrate tot the patterned beam, and any combinations thereof.
- a selected operational mode results in a particular velocity and/or different acceleration or deceleration for the transport of the substrate and/or substrate table. It is possible that certain steps in alignment procedures can be shortened and/or cancelled at all, especially if these procedures are involved with achieving an accuracy not needed for a selected operational mode. Iterative procedures can be prolonged or shortened, depending on the selected operational mode. Also the settling time, the time in which disturbances due to movements and/or thermal instability damp out to an acceptable level can be shortened or prolonged, as the acceptable level is related to the required accuracy and thus to the selected operational mode.
- the apparatus is arranged to select in each operational mode particular operation settings, wherein each operation setting comprises a combination of a predetermined period of time in which a particular process is to be carried out by the lithographic apparatus and a predetermined level of accuracy with which that process is to be carried out. This allows for selecting a set of combinations with predetermined settings, providing convenience to the user and a fast preparation for operation of the apparatus.
- the apparatus comprises a control-unit which is arranged to determine of at least one process step of the process a process time for obtaining a required accuracy or a process accuracy for obtaining a required process time. This allows for optimizing the manufacturer of a device. This embodiment may employ an expert system for this optimizing.
- a device manufacturing method comprising providing a substrate that is at least partially covered by a layer of radiation-sensitive material; conditioning a beam of radiation; applying a patterning device to configure the conditioned beam of radiation with a desired pattern in its cross-section; projecting the patterned beam of radiation onto a target portion of the substrate; and selecting one out of at least two different operational modes.
- a first operational mode is associated with performing a process within a first time period at a first level of accuracy and a second operational mode is associated with performing the process within a second time period at a second level of accuracy.
- the first time period is shorter than the second time period and the first level of accuracy is lower than the second level of accuracy.
- UV radiation e.g. with a wavelength of 365, 248, 193, 157 or 126 nm
- EUV extreme ultra-violet
- particle beams such as ion beams or electron beams.
- FIG. 1 depicts a lithographic projection apparatus according to a first embodiment of the invention.
- FIG. 2 depicts a lithographic projection apparatus according to a second embodiment of the invention.
- FIG. 1 schematically depicts a lithographic projection apparatus 1 according to a particular embodiment of the invention.
- the apparatus comprises:
- the apparatus is of a transmissive type (i.e. has a transmissive mask). However, in general, it may also be of a reflective type, for example (with a reflective mask). Alternatively, the apparatus may employ another kind of patterning device, such as a programmable mirror array of a type as referred to above.
- the source LA produces a beam of radiation.
- This beam is fed into an illumination system (illuminator) IL, either directly or after having traversed conditioning means, such as a beam expander Ex, for example.
- the illuminator IL may comprise adjusting means AM for setting the outer and/or inner radial extent (commonly referred to as ⁇ -outer and ⁇ -inner, respectively) of the intensity distribution in the beam.
- ⁇ -outer and ⁇ -inner commonly referred to as ⁇ -outer and ⁇ -inner, respectively
- it will generally comprise various other components, such as an integrator IN and a condenser CO.
- the beam PB impinging on the mask MA has a desired uniformity and intensity distribution in its cross-section.
- the source LA produces a beam of radiation.
- This beam is fed into an illumination system (illuminator) IL, either directly or after having traversed conditioning means, such as for example a beam expander Ex.
- the illuminator IL may comprise adjusting means AM for adjusting the angular intensity distribution in the beam.
- adjusting means AM for adjusting the angular intensity distribution in the beam.
- the illuminator IL will generally comprise various other components, such as an integrator IN and a condenser CO. In this way, the beam PB impinging on the mask MA has a desired uniformity and intensity distribution in its cross-section.
- the source LA may be within the housing of the lithographic projection apparatus (as is often the case when the source LA is a mercury lamp, for example), but that it may also be remote from the lithographic projection apparatus, the radiation beam which it produces being led into the apparatus (e.g. with the aid of suitable directing mirrors); this latter scenario is often the case when the source LA is an excimer laser.
- the current invention and claims encompass both of these scenarios.
- the beam PB subsequently impinges on the mask MA, which is held on a mask table MT.
- the beam PB passes through the lens PL, which focuses the beam PB onto a target portion C of the substrate W.
- the substrate table WT can be moved accurately, e.g. so as to position different target portions C in the path of the beam PB.
- the first positioning mechanism PM can be used to accurately position the mask MA with respect to the path of the beam PB, e.g. after mechanical retrieval of the mask MA from a mask library, or during a scan.
- the mask table MT may just be connected to a short stroke actuator, or may be fixed.
- Mask MA and substrate W may be aligned using mask alignment marks M 1 , M 2 and substrate alignment marks P 1 , P 2 .
- the depicted apparatus can be used in different modes:
- the embodiment shown in FIG. 1 further comprises a selection system SS for selecting one out of at least two different operational modes of the lithographic apparatus.
- a process is performed during a first period of time and with a first level of accuracy.
- a process is performed in a second period of time and with a second level of accuracy.
- the selection system (SS) shown in FIG. 1 comprises a Radiation System Control unit (RSC), a Patterning Device Control unit (PMC), Projection System Control unit (PSC), and substrate or Wafer Table Control unit (WTC).
- RSC Radiation System Control unit
- PMC Patterning Device Control unit
- PSC Projection System Control unit
- WTC Wafer Table Control unit
- the PMC is connected with the first positioning mechanism PM
- the WTC is connected with the second positioning mechanism PW. It is possible that the selection system comprises only one or some of these control units.
- Accuracy of the alignment procedure maybe altered by changing a cut off value, which is a value at which an iterative process of alignment will be stopped.
- the selection system SS is arranged to be controlled by a user. However, the user needs to address each control unit separately. It is possible that the selection system is arranged to allow for selection one out of a large number of operational settings.
- FIG. 2 illustrates an alternative embodiment of a lithographic apparatus according to the invention.
- This embodiment is similar to the first embodiment and may comprise all the features described for the first embodiment.
- the apparatus additionally includes a User Interface (UL).
- the selection system SS may be controllable via the User Interface U 1 .
- the selection system SS may again comprise, for instance, one or more of the above-mentioned control units, RSC, PMC, PCS and WTC.
- the number of operating settings are related to each other according to a predetermined relationship.
- the user interface UI may comprise a display on which the relationship can be visualized preferably in a graph, preferably as a line which may be continuous. This line may further be free from steps.
- Each operational setting comprises a combination of a predetermined time period, in which a particular process is to be carried out by the lithographic apparatus, and a predetermined level of accuracy with which the process is to be carried out.
- the apparatus comprises a control-unit which is arranged to determine of at least one process step of the process a process time for obtaining required accuracy or a process accuracy for obtaining a required process time.
- This embodiment may employ an expert system for optimizing the manufacture of a device in correspondence with a desired accuracy, a desired throughput, or both.
- a device manufacturing method that comprises (a) providing a substrate that is at least partially covered by a layer of radiation-sensitive material; (b) conditioning a beam of radiation; (c) applying a patterning device to configure the conditioned beam of radiation with a desired pattern in its cross-section; (d) projecting the patterned beam of radiation onto a target portion of the substrate; and (e) selecting one out of at least two different operational modes.
- the first operational mode is associated with performing a process within a first time period at a first level of accuracy and the second operational mode is associated with performing the process within a second time period at a second level of accuracy. As discussed above, the first time period is shorter than the second time period and the first level of accuracy is lower than the second level of accuracy.
- the process referred to in the above descriptions may include, but is not limited to, one or more of the processing tasks: (a) transporting the substrate and/or substrate holder; (b) settling the substrate after transport; (c) aligning the radiation system; (d) settling the radiation system after aligning; (e) aligning the support structure; (f) settling the support structure after aligning; (g) aligning the patterning device; (h) settling the patterning device after aligning; (i) aligning the projection system; (j) settling the patterning device after aligning; (k) tilting the substrate; (l) settling after tilting; (m) focusing the projection system; (n) exposing the substrate to the patterned beam; and any combinations thereof.
- Each one of these mentioned processing tasks may achieve specific additional benefits through the use of the principles of the present invention.
- Each processing task can, of course, be subdivided in sub-processing tasks.
- exposing of the substrate to the patterned beam may comprise a number of times the beam flashes and the intensity of each flash. Both the number of times and the intensity may be subjected to alterations for the purpose of this invention.
- the user interface UI in FIG. 2 is shown to be connected to the RSC, PMC, PSC and the WTC, it is also possible that the user interface UI is capable of wirelessly controlling the selection system SS.
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Abstract
Description
-
- a mask: the concept of a mask is well known in lithography, and it includes mask types such as binary, alternating phase-shift, and attenuated phase-shift, as well as various hybrid mask types. Placement of such a mask in the radiation beam causes selective transmission (in the case of a transmission mask) or reflection (in the case of a reflective mask) of the radiation impinging on the mask, according to the pattern on the mask. In the case of a mask, the support structure will generally be a mask table/holder/holder, which ensures that the mask can be held at a desired position in the incoming radiation beam, and that it can be moved relative to the beam if so desired;
- a programmable mirror array: one example of such a device is a matrix-addressable surface having a visco-elastic control layer and a reflective surface. The basic principle behind such an apparatus is that (for example) addressed areas of the reflective surface reflect incident light as diffracted light, whereas unaddressed areas reflect incident light as non-diffracted light. Using an appropriate filter, the non-diffracted light can be filtered out of the reflected beam, leaving only the diffracted light behind; in this manner, the beam becomes patterned according to the addressing pattern of the matrix-addressable surface. An alternative embodiment of a programmable mirror array employs a matrix arrangement of tiny mirrors, each of which can be individually tilted about an axis by applying a suitable localized electric field, or by employing piezoelectric actuation mechanism. Once again, the mirrors are matrix-addressable, such that addressed mirrors will reflect an incoming radiation beam in a different direction to unaddressed mirrors; in this manner, the reflected beam is patterned according to the addressing pattern of the matrix-addressable mirrors. The required matrix addressing can be performed using suitable electronic means. In both of the situations described here above, the patterning device can comprise one or more programmable mirror arrays. More information on mirror arrays as here referred to can be gleaned, for example, from United States patents U.S. Pat. No. 5,296,891 and U.S. Pat. No. 5,523,193, and PCT patent applications WO 98/38597 and WO 98/33096, which are incorporated herein by reference. In the case of a programmable mirror array, the support structure may be embodied as a frame or table, for example, which may be fixed or movable as required; and
- a programmable LCD array: an example of such a construction is given in United States patent U.S. Pat. No. 5,229,872, which is incorporated herein by reference. As above, the support structure in this case may be embodied as a frame or table, for example, which may be fixed or movable as required.
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- a radiation system Ex, IL: for supplying a projection beam PB of radiation (e.g. EUV, DUV, or UV radiation). In this particular case, the radiation system also comprises a radiation source LA;
- •a first object table (mask table/holder/holder) MT: provided with a mask holder for holding a mask MA (e.g. a reticle), and connected to first positioning mechanism for accurately positioning the mask with respect to item PL;
- •a second object table (substrate table/holder) WT: provided with a substrate holder for holding a substrate W (e.g. a resist-coated silicon wafer), and connected to second positioning mechanism for accurately positioning the substrate with respect to item PL;
- •a projection system (“lens”) PL: for example, a mirror or refractive lens system that images an irradiated portion of the mask MA onto a target portion C (comprising one or more dies) of the substrate W.
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- step mode: the mask table MT is kept essentially stationary, and an entire mask image is projected in one go (i.e. a single “flash”) onto a target portion C. The substrate table WT is then shifted in the X and/or Y directions so that a different target portion C can be irradiated by the beam PB;
- scan mode; essentially the same scenario applies, except that a given target portion C is not exposed in a single “flash”. Instead, the mask table MT is movable in a given direction (the so-called “scan direction”, e.g. the Y-direction) with a speed ν, so that the projection beam PB is caused to scan over a mask image; concurrently, the substrate table WT is simultaneously moved in the same or opposite direction at a speed V=M ν, in which M is the magnification of the lens PL (typically, M=1/4 or 1/5). In this manner, a relatively large target portion C can be exposed, without having to compromise on resolution; and
- other mode: the mask table MT is kept essentially stationary holding a programmable patterning device, and the substrate table WT is moved or scanned while a pattern imparted to the projection beam is projected onto a target portion C. In this mode, generally a pulsed radiation source is employed and the programmable patterning device is updated as required after each movement of the substrate table WT or in between successive radiation pulses during a scan. This mode of operation can be readily applied to maskless lithography that utilizes programmable patterning device, such as a programmable mirror array of a type as referred to above.
Claims (24)
Applications Claiming Priority (2)
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EP03077301A EP1500987A1 (en) | 2003-07-21 | 2003-07-21 | Lithographic apparatus, device manufacturing method, and device manufactured thereby |
EP03077301.4 | 2003-07-21 |
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US20050041227A1 US20050041227A1 (en) | 2005-02-24 |
US7294844B2 true US7294844B2 (en) | 2007-11-13 |
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EP1170636A2 (en) | 2000-07-07 | 2002-01-09 | Nikon Corporation | Exposure apparatus and surface position adjustment unit |
US20020078429A1 (en) | 2000-11-29 | 2002-06-20 | Nikon Corporation | Design method for control system, control system, adjustment method for control system, exposure method, and exposure apparatus |
-
2003
- 2003-07-21 EP EP03077301A patent/EP1500987A1/en not_active Withdrawn
-
2004
- 2004-07-20 US US10/894,368 patent/US7294844B2/en active Active
- 2004-07-20 JP JP2004210947A patent/JP2005045246A/en active Pending
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JPS6187330A (en) | 1984-10-01 | 1986-05-02 | Canon Inc | semiconductor manufacturing equipment |
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US6046792A (en) | 1996-03-06 | 2000-04-04 | U.S. Philips Corporation | Differential interferometer system and lithographic step-and-scan apparatus provided with such a system |
US5969441A (en) | 1996-12-24 | 1999-10-19 | Asm Lithography Bv | Two-dimensionally balanced positioning device with two object holders, and lithographic device provided with such a positioning device |
WO1998033096A1 (en) | 1997-01-29 | 1998-07-30 | Micronic Laser Systems Ab | Method and apparatus for the production of a structure by focused laser radiation on a photosensitively coated substrate |
WO1998038597A2 (en) | 1997-02-28 | 1998-09-03 | Micronic Laser Systems Ab | Data-conversion method for a multibeam laser writer for very complex microlithographic patterns |
WO1998040791A1 (en) | 1997-03-10 | 1998-09-17 | Koninklijke Philips Electronics N.V. | Positioning device having two object holders |
EP1170636A2 (en) | 2000-07-07 | 2002-01-09 | Nikon Corporation | Exposure apparatus and surface position adjustment unit |
US20020078429A1 (en) | 2000-11-29 | 2002-06-20 | Nikon Corporation | Design method for control system, control system, adjustment method for control system, exposure method, and exposure apparatus |
Also Published As
Publication number | Publication date |
---|---|
EP1500987A1 (en) | 2005-01-26 |
US20050041227A1 (en) | 2005-02-24 |
JP2005045246A (en) | 2005-02-17 |
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